Methods and systems for monitoring machinery

ABSTRACT

A method and system for operating a facility having a plurality of equipment combinations wherein each equipment combination is operating interactively with at least one of another of the plurality of equipment combination is provided. The method includes receiving, in real-time, for each of the plurality of equipment combinations, a plurality of measured process parameters, determining at least one derived quantity from the plurality of measured process parameters, and recommending a change to an equipment operation based on the measured process parameters and the derived quantities.

BACKGROUND OF THE INVENTION

This invention relates generally to the monitoring of machinery, andmore particularly to methods and systems for continuously monitoring aplurality of machines.

At least some known machinery monitoring systems, monitor machinedrivers, for example, motors and turbines, or machine driven components,such as, pumps, compressors, and fans. Other known monitoring systemsmonitor process parameters of a process, for example, piping systems,and machine environmental conditions, such as machine vibration, machinetemperature, and machine oil condition. Typically, such monitoringsystems are supplied by an original equipment manufacture (OEM) that isresponsible for only a portion of a facility, for example, a specificpiece of equipment, and as such, the OEM may only provide monitoring forequipment provided by that OEM. However, industrial facilities such aspower plants, refineries, factories, and commercial facilities, such as,hospitals, high-rise buildings, resorts, and amusement parks may utilizea considerable plurality of machine drivers and driven equipmentdependently interconnected to form various process systems. Anarchitect/engineer may integrate such equipment for an owner or operatorof the facility. Monitoring systems supplied by different OEMs maycommunicate with external data collection and control systems, such asdistributed control systems (DCS) located at sites that are remote fromthe monitored equipment, for example, control rooms and/or operatingareas.

Typically, machine monitoring systems are primarily focused on providingoperating indications and controls, and/or trending or dataloggingcapabilities for future reconstruction of abnormal events. Machinemonitoring systems that provide useful maintenance related data, such asvibration data, limit data collection and analysis to discretecomponents isolated from other components that may be operated in aninterconnected system. For example, monitoring systems may collectvibration data for a motor/pump combination but, analyze each machineseparately, ignoring the interdependence between each individualmachine. If the analysis does account for the combination acting as aconnected combination, the known systems only consider the vibrationparameters collected, and any further analysis of external causes orsources for the particular vibration characteristics of the motor/pumpcombination is done manually by a plant engineer performingtroubleshooting or predictive maintenance activities. However, themotor/pump combination may be part of a larger process system whereinany number of process parameters from other motor/pump combinationsand/or other equipment may contribute or affect the vibrationcharacteristics of the motor/pump combination.

BRIEF DESCRIPTION OF THE INVENTION

In one aspect, a method and system for operating a facility having aplurality of equipment combinations wherein each equipment combinationis operating interactively with at least one of another of the pluralityof equipment combination is provided. The method includes receiving, inreal-time, for each of the plurality of equipment combinations, aplurality of measured process parameters, determining at least onederived quantity from the plurality of measured process parameters, andrecommending a change to an equipment operation based on the measuredprocess parameters and the derived quantities.

In another aspect, an integrated monitoring and control system for aplant having a plurality of equipment combinations operatinginteractively with each other and with individual equipment wherein theequipment combinations are operated to maintain selected plantoperational conditions is provided The integrated monitoring and controlsystem includes a plurality of sensors operatively coupled to theequipment combinations, the plurality of sensors measuring processparameters for monitoring plant operation and assessing equipmentcombination condition, and providing output signals to said monitoringand control system, a derived quantity layer communicatively coupled toa data bus wherein the derived quantity layer is configured to receivethe measured process parameters; and compute values for processparameters using the measured process parameters. The integratedmonitoring and control system also includes a rule set layer comprisingat least one rule associated with at least some of the plurality ofequipment combinations for determining a health of the equipmentcombination, and a recommendation layer for correlating the health ofthe equipment combination to at least one of a mitigating procedure, amaintaining procedure, and an operation procedure.

In yet another aspect, a computer program embodied on a computerreadable medium for monitoring a plant is provided. The plant includes aplurality of equipment combinations operating interactively with eachother and with individual equipment. The program includes a code segmentthat controls a computer that receives a plurality of process parametersfrom sensors operatively coupled to the equipment combinations andindividual equipment and then derives values for process parametersusing the measured process parameters, selects a rule from a set ofrules comprising a plurality of commands that direct data analysis foreach at least one of measured process parameter, a derived quantity, aplurality of measured process parameters and a derived quantitiesassociated with an equipment combination, and recommends at least one ofa mitigating procedure, a maintaining procedure, and an operationprocedure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram an exemplary equipment layout of an industrialplant;

FIG. 2 is a block diagram of an exemplary embodiment of a networkarchitecture of a plant control system implementing the continuousintegrated machinery monitoring system (CIMMS) shown in FIG. 1;

FIG. 3 is a perspective view of an exemplary motor/pump combination thatmay be one of a plurality driver/driven machine combinations analyzed bythe CIMMS shown in FIG. 1;

FIG. 4 is a block diagram of a data control structure that may be usedwith the DCS to implement an exemplary embodiment of the CIMMS shown inFIG. 1; and

FIG. 5 is a data flow diagram of an exemplary data flow path formonitoring the equipment combination shown in FIG. 3.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 is a block diagram an exemplary equipment layout of an industrialplant 10. Industrial plant 10 may include a plurality of pumps, motors,fans, and process monitoring sensors that are coupled in flowcommunication through interconnecting piping and coupled in signalcommunication with a control system through one or more remoteinput/output (I/O) modules and interconnecting cabling and/or wirelesscommunication. In the exemplary embodiment, industrial plant 10 includesa distributed control system (DCS) 20 including a network backbone 22.Network backbone 22 may be a hardwired data communication pathfabricated from twisted pair cable, shielded coaxial cable or fiberoptic cable, for example, or may be at least partially wireless. DCS 20may also include a processor 24 that is communicatively coupled toequipment that is located at industrial plant 10, or at remotelocations, through network backbone 22. It is to be understood that anynumber of machines may be communicatively connected to the networkbackbone 22. A portion of the machines may be hardwired to networkbackbone 22, and another portion of the machines may be wirelesslycoupled to backbone 22 via a base station 26 that is communicativelycoupled to DCS 20. Wireless base station 26 may be used to expand theeffective communication range of DCS 20, such as with equipment orsensors located remotely from industrial plant 10 but, stillinterconnected to one or more systems within industrial plant 10.

DCS 20 may be configured to receive and display operational parametersassociated with a plurality of equipment, and to generate automaticcontrol signals and receive manual control inputs for controlling theoperation of the equipment of industrial plant 10. In the exemplaryembodiment, DCS 20 may include a software code segment configured tocontrol processor 24 to analyze data received at DSC 20 that allows foron-line monitoring and diagnosis of the industrial plant machines.Process parameter data may be collected from each machine, includingpumps and motors, associated process sensors, and local environmentalsensors, including for example, vibration, seismic, ambient temperatureand ambient humidity sensors. The data may be pre-processed by a localdiagnostic module or a remote input/output module, or may transmitted toDCS 20 in raw form.

Specifically, industrial plant 10 may include a first process system 30that includes a pump 32 coupled to a motor 34 through a coupling 36, forexample a hydraulic coupling, and interconnecting shafts 38. Thecombination of pump 32, motor 34, and coupling 36, although comprisingseparate components, may operate as a single system, such thatconditions affecting the operation of one component of the combinationmay effect each of the other components of the combination. Accordingly,condition monitoring data collected from one component of thecombination that indicates a failure of a portion of the component or animpending failure of the component may be sensed at the other componentsof the combination to confirm the failure of the component and/orfacilitate determining a source or root cause of the failure.

Pump 32 may be connected to a piping system 40 through one or morevalves 42. Valve 42 may include an actuator 44, for example, but, notlimited to, an air operator, a motor operator, and a solenoid. Actuator44 may be communicatively coupled to DCS 20 for remote actuation andposition indication. In the exemplary embodiment, piping system 40 mayinclude process parameter sensors, such as a pressure sensor 46, a flowsensor 48, a temperature sensor 50, and a differential pressure (DP)sensor 52. In an alternative embodiment, piping system 40 may includeother sensors, such as turbidity, salinity, pH, specific gravity, andother sensors associated with a particular fluid being carried by pipingsystem 40. Sensors 46, 48, 50 and 52 may be communicatively coupled to afield module 54, for example, a preprocessing module, or remote I/Orack.

Motor 34 may include one or more of a plurality of sensors (not shown)that are available to monitor the operating condition of electrodynamicmachines. Such sensors may be communicatively coupled to field module 54through an interconnecting conduit 56, for example, copper wire orcable, fiber cable, and wireless technology.

Field module 54 may communicate with DCS 20 through a network segment58. The communications may be through any network protocol and may berepresentative of preprocessed data and or raw data. The data may betransmitted to processor 24 continuously in a real-time environment orto processor 24 intermittently based on an automatic arrangement or arequest for data from processor 24. DCS 20 includes a real time clock incommunication with network backbone 22, for time stamping processvariables for time-based comparisons.

Piping system 40 may include other process components, such as a tank 60that may include one or more of a plurality of sensors available formonitoring process parameters associated with tanks, such as, a tanklevel sensor 62. Tank 60 may provide a surge volume for fluid pumped bypump 32 and/or may provide suction pressure for downstream components,such as, skid 64. Skid 64 may be a pre-engineered and prepackagedsubsystem of components that may be supplied by an OEM. Skid 64 mayinclude a first pump 66 and a second pump 68. In the exemplaryembodiment, first pump is coupled to a motor that is directly coupled toa power source (not shown) through a circuit breaker (not shown) thatmay be controlled by DCS 20. Second pump 68 is coupled to a motor 72that is coupled to the power source through a variable speed drive (VSD)74 that controls a rotational speed of motor 72 in response to commandsfrom a skid controller 76. Each of pumps 66 and 68, and motors 70 and72, and VSD 74 may include one or more sensors associated withrespective operating parameters of each type of equipment as describedabove in relation to pump/motor/coupling 32, 34, and 36 combination.Skid controller 76 receives signals from the sensors and may transmitthe signals to DCS 20 without preprocessing or after processing the datain accordance with predetermined algorithms residing within skidcontroller 76. Skid controller 76 may also process the signals andgenerate control signals for one or more of pumps 66 and 68, and motors70 and 72, and VSD 74 without transmitting data to DCS 20. Skidcontroller may also receive commands from DCS 20 to modify the operationof skid 64 in accordance therewith.

A second piping system 80 may include a fan 82 that receives air from anambient space 84 and directs the air through a valve or damper 86 to acomponent, such as a furnace 88. Damper 86 may include position sensors90 and 92 to detect an open and closed position of damper 86. Furnace 88may include a damper 94 that may be operated by actuator 96, which maybe, for example, a motor actuator, a fluid powered piston actuator, orother actuator, which may be controlled remotely by DCS 20 through asignal transmitted through a conduit (not shown). A second fan 98 maytake a suction on furnace 88 to remove combustion gases from furnace 88and direct the combustion gases to a smoke stack or chimney (not shown)for discharge to ambient space 84. Fan 98 may be driven by a motor 100through a shaft 102 coupled between fan 98 and motor 100. A rotationalspeed of motor 100 may be controlled by a VSD 104 that may becommunicatively coupled to DCS 20 though network backbone 22. Fan 82 maybe driven by an engine 106, such as an internal combustion engine, or asteam, water, wind, or gas turbine, or other driver, through a coupling108, which may be hydraulic or other power conversion device. Each ofthe components may include various sensors and control mechanisms thatmay be communicatively coupled to DCS 20 through network backbone 22 ormay communicate with DCS 20 through a wireless transmitter/receiver 108to wireless base station 26.

DCS 20 may operate independently to control industrial plant 10, or maybe communicatively coupled to one or more other control systems 110.Each control system may communicate with each other and DCS 20 through anetwork segment 112, or may communicate through a network topology, forexample, a star (not shown).

A continuous integrated machinery monitoring system (CIMMS) 114 may be aseparate add-on hardware device that communicates with DCS 20 and othercontrol systems 110. CIMMS 114 may also be embodied in a softwareprogram segment executing on DCS 20 and/or one or more of the othercontrol systems 110. Accordingly, CIMMS 114 may operate in a distributedmanner, such that a portion of the software program segment executes onseveral processors concurrently. As such, CIMMS 114 may be fullyintegrated into the operation of DCS 20 and other control systems 110.CIMMS 114 analyzes data received by DCS 20 and the other control systems110 determine a health the machines and/or a process employing themachines using a global view of the industrial plant 10. CIMMS 114analyzes combinations of drivers and driven components, and processparameters associated with each combination to correlate machine healthfindings of one machine to machine health indications from othermachines in the combination, and associated process or environmentaldata. CIMMS 114 uses direct measurements from various sensors availableon each machine and derived quantities from all or a portion of all thesensors in industrial plant 10. CIMMS 114, using predetermined analysisrules, determines a failure or impending failure of one machine andautomatically, in real-time correlates the data used to determine thefailure or impending failure with equivalent data derived from theoperating parameters of other components in the combination or fromprocess parameters. CIMMS 114 also provides for performing trendanalysis on the machine combinations and displaying data and/or trendsin a variety of formats so as to afford a user of CIMMS 114 an abilityto quickly interpret the health assessment and trend informationprovided by CIMMS 114.

Although various combinations of machines are generally illustrated asmotor/pump, motor/fan, or engine/fan combinations, it should beunderstood these combinations are exemplary only, and CIMMS isconfigured to analyze any combination of driver/driven machines.

FIG. 2 is a block diagram of an exemplary embodiment of a networkarchitecture of a plant control system 200 implementing CIMMS 114 (shownin FIG. 1). Components in system 200, identical to components of system10 (shown in FIG. 1), are identified in FIG. 2 using the same referencenumerals as used in FIG. 1. In the exemplary embodiment, system 200includes a server system 202 and client systems 204. Server system 202further includes a database server 206, an application server 208, a webserver 210 a fax server 212, a directory server 214, and a mail server216. Each of servers 206, 208, 210, 212, 214, and 216 may be embodied insoftware executing on server system 202, or any combinations of servers206, 208, 210, 212, 214, and 216 may be embodied alone or in combinationon separate server systems coupled in a local area network (LAN) (notshown). A disk storage unit 220 is coupled to server system 202. Inaddition, a workstation 222, such as a system administrator'sworkstation, a user workstation, and/or a supervisor's workstation arecoupled to a LAN 224. Alternatively, workstations 222 are coupled to LAN224 using an Internet link 226 or are connected through an Intranet.

Each workstation 222 may be a personal computer having a web browser.Although the functions performed at the workstations typically areillustrated as being performed at respective workstations 222, suchfunctions can be performed at one of many personal computers coupled toLAN 224. Workstations 222 are described as being associated withseparate exemplary functions only to facilitate an understanding of thedifferent types of functions that can be performed by individuals havingaccess to LAN 224.

Server system 202 is configured to be communicatively coupled to variousindividuals, including employees 228 and to third parties, e.g., serviceproviders 230. The communication in the exemplary embodiment isillustrated as being performed using the Internet, however, any otherwide area network (WAN) type communication can be utilized in otherembodiments, i.e., the systems and processes are not limited to beingpracticed using the Internet.

In the exemplary embodiment, any authorized individual having aworkstation 232 can access CIMMS 114. At least one of the client systemsmay include a manager workstation 234 located at a remote location.Workstations 222 may be embodied on personal computers having a webbrowser. Also, workstations 222 are configured to communicate withserver system 202. Furthermore, fax server 212 communicates withremotely located client systems, including a client system 236 using atelephone link (not shown). Fax server 212 is configured to communicatewith other client systems 228, 230, and 234, as well.

Computerized modeling and analysis tools of CIMMS 114, as describedbelow in more detail, are stored in server 202 and can be accessed by arequester at any one of client systems 204. In one embodiment, clientsystems 204 are computers including a web browser, such that serversystem 202 is accessible to client systems 204 using the Internet.Client systems 204 are interconnected to the Internet through manyinterfaces including a network, such as a local area network (LAN) or awide area network (WAN), dial-in-connections, cable modems and specialhigh-speed ISDN lines. Client systems 204 could be any device capable ofinterconnecting to the Internet including a web-based phone, personaldigital assistant (PDA), or other web-based connectable equipment.Database server 206 is connected to a database 240 containinginformation about industrial plant 10, as described below in greaterdetail. In one embodiment, centralized database 240 is stored on serversystem 202 and can be accessed by potential users at one of clientsystems 204 by logging onto server system 202 through one of clientsystems 204. In an alternative embodiment, database 240 is storedremotely from server system 202 and may be non-centralized.

Other industrial plant systems may provide data that is accessible toserver system 202 and/or client systems 204 through independentconnections to LAN 224. An interactive electronic tech manual server 242services requests for machine data relating to a configuration of eachmachine. Such data may include operational capabilities, such as pumpcurves, motor horsepower rating, insulation class, and frame size,design parameters, such as dimensions, number of rotor bars or impellerblades, and machinery maintenance history, such as field alterations tothe machine, as-found and as-left alignment measurements, and repairsimplemented on the machine that do not return the machine to itsoriginal design condition. Additionally, server system 202 may sendpredetermined and/or selectable setpoints to DCS 20. Such setpoint maybe determined based on a predetermined limitation on an equipmentcombination to limit its capability based on a machinery history,as-found, and/or as left inspection results. Other rule determinationsmay also transmitted to DCS 20.

A portable vibration monitor 244 may be intermittently coupled to LANdirectly or through a computer input port such as ports included inworkstations 222 or client systems 204. Typically, vibration data iscollected in a route, collecting data from a predetermined list ofmachines on a periodic basis, for example, monthly or other periodicity.Vibration data may also be collected in conjunction withtroubleshooting, maintenance, and commissioning activities. Such datamay provide a new baseline for algorithms of CIMMS 114. Process data maysimilarly, be collected on a route basis or during troubleshooting,maintenance, and commissioning activities. Certain process parametersmay not be permanently instrumented and a portable process datacollector 244 may be used to collect process parameter data that can bedownloaded to plant control system 200 so that it is accessible to CIMMS114. Other process parameter data, such as process fluid chemistryanalyzers and pollution emission analyzers may be provided to plantcontrol system 200 through a plurality of on-line monitors 246.

Electrical power supplied to various machines or generated by generatorswithin industrial plant 10 may be monitored by a relay 246, for example,but, not limited to a protection relay, associated with each machine.Typically, such relays 246 are located remotely from the monitoredequipment in a motor control center (MCC) or in switchgear 250 supplyingthe machine. In addition, to relay 246, switchgear 250 may also includea supervisory control and data acquisition system (SCADA) that providesCIMMS 114 with a condition of power supply or power delivery system (notshown) equipment located at the industrial plant 10, for example, in aswitchyard, or remote transmission line breakers and line parameters.

FIG. 3 is a perspective view of an exemplary motor/pump combination 300that may be one of a plurality driver/driven machine combinationsanalyzed by CIMMS 114. It should be understood that CIMMS 114 may beused to monitor and analyze rotating equipment including pumps,turbines, fans, blowers, compressors, non-rotating equipment, such as,transformers and catalytic reactors, or other types of equipment. A pumpand motor combination is illustrated for purposes of example only. Pumpand motor combination 300 includes motor 302 and a pump 304. Motor 302may be an electric motor, diesel engine or turbine, or other powersource. Motor 302 is operatively connected to pump 304 via coupling 16.Pump 304 includes an inlet 308 and an outlet 310. A control valve 311may be located downstream from outlet 310 of pump 304. Control valve 311may be responsive to commands received from DCS 20 for operating pumpand motor combination, 300 within selected operating design parameters.Control valve 311 is also used to control flow through pump 304 tosatisfy piping and process system requirements. Closing control valve311, by providing a signal to a valve operator 313, increases fluidresistance to flow and causes pump 304 to operate at a higher pressureand a lower flow rate. Similarly, opening control valve 311 results inreduced fluid resistance, increased flow rate and a relatively lowerpressure.

A head tank (not shown) may be located upstream from inlet 308 of pump304. The head tank may include a level sensor and may provide pump 304with sufficient head pressure to facilitate avoiding a cavitationcondition from occurring in pump 304. Process sensors may include anoutlet pressure sensor 312, which is positioned proximate outlet 310 ofpump 304, for determining pump outlet pressure. Process sensors may alsoinclude a flowmeter 314 for determining a flow rate of a process fluiddownstream of pump 304, a temperature sensor 316, which is proximatelypositioned upstream or downstream of pump 304 for determiningtemperature of the process fluid, an inlet pressure sensor 318, which ispositioned proximate pump inlet 308 for determining rotating machineinlet pressure, and a valve position sensor 320.

Valve position sensor 320 may be coupled to control valve 311 andcommunicate with an input/output (I/O) device 322 for convertingelectrical signals to digital signals, preprocessing sensor signals,and/or to transmit the signals to DCS 20 as raw data. Valve positionsensor 320 is used to determine the position of control valve 311, andvalve position sensor 320 may provide input for a confirmatory methodfor calculating flow through pump 304. Flow through valve 311 can becalculated from a position of control valve 311, a pressure drop acrossvalve 311 and known fluid properties and pump geometry and/or a pumpcurve supplied with the pump 304. The fluid properties, pump geometry,and/or a pump curve may be stored in a database associated with CIMMS114, such as, for example, on interactive electronic tech manual server242. Flow through valve 311 may then be stored as original data. Thisinformation enables a baseline head versus flow performance referencecurve to be developed in the absence of a pump curve supplied from thepump supplier, and provides an alternate method to confirm operation ofsensors monitoring pump 304. For example, when flowmeter 314 fails, thefailure may be isolated to flowmeter 314 rather than a failure of pump304 or other component of combination 300.

Additional sensors that may be used include, but are not limited to,vibration sensors, which may be embodied in an accelerometer 324, othervibration sensors may be proximity sensors, such as a pump outboardproximity sensor 326, a pump inboard proximity sensor 328, a transducera once-per-revolution event, such as a Keyphasor® 330, and a thrustsensor 332. Motor 302 may include a winding temperature sensor 334 fordetermining an overheating and or overload condition in motor 302, abearing temperature sensor 336 to confirm an operating condition of amotor bearing 338. A current and voltage of the electrical energysupplied to motor 302 may be monitored locally or remotely at the MCCsupplying motor 302, or may be monitored by relay 246.

A variable speed drive (VSD) 340 may be electrically coupled to motor302 through a cable 342. VSD 340 may also be communicatively coupled toDCS 20 to receive commands to change a rotational speed of motor 302 toprovide a selected flow and pressure.

FIG. 4 is a block diagram of a data control structure 400 that may beused with DCS 20 to implement an exemplary embodiment of CIMMS 114(shown in FIG. 1). DCS 20 may include CIMMS 114 executing on processor24 within DCS 20. Alternatively, CIMMS 114 may operate separately formDCS 20 as a standalone processing platform, such as, a computer,workstation, and/or client system processing machine.

DCS 20 may include a plurality of hardware layers 402 that performvarious functions within DCS 20. For example, a communications layer 404may receive communications from a plurality of devices through networkbackbone 22. At least some devices are process monitoring devices suchas, for example, outlet pressure sensor 312, flowmeter 314, temperaturesensor 316, inlet pressure sensor 318, valve position sensor 320,input/output (I/O) device 322, accelerometer 324, pump outboardproximity sensor 326, pump inboard proximity sensor 328, keyphasor 330,thrust sensor 332, winding temperature sensor 334, and bearingtemperature sensor 336. Additionally, sensors from other motor/pumpcombinations, driver/driven combinations, monitored electricalequipment, pollution control equipment, and environmental sensorsassociated with plant 10 may provide communications to DCS 20 throughnetwork backbone 22, or directly through dedicated inputs. Otherdistributed control systems and skid controllers may communicate withDCS 20 as well.

Data received by communications layer 404 may be preprocessed bycommunications layer 404 before being transmitted to data bus 406, anddata being transmitted by communications layer 404 to network backbone22 may be post processed as needed for compatibility with variousprotocols used by devices communicatively coupled to communicationslayer 404. DCS 20 may include a data processing layer 406 that isconfigured to receive data from data bus 406. Data processing layer 406may compare received data values to predetermined limits, check forfaulty instruments and sensors. DCS 20 may also include an archive layer408 wherein data may be stored for later processing, trending,time-based analysis, and outputting to output devices in a userselectable format. A data analyzer layer 410 may be used to providesignal processing of data received through communications layer 404.Such signal processing may include, but is not limited to average,standard deviation, peak detection, correlation, fast fourier transform(FFT), and demodulation. Specific calculations may be mathematicalalgorithms, logical rule based, and/or soft computing that exploit thetolerance for imprecision, uncertainty and partial truth to achievetractability, robustness and low solution cost, including, for example,fuzzy logic, and/or neural network processes involving multidimensionalchains of calculations and decisions. The calculations may also includestatistical analyses and database management processes. For somealgorithms, calculations are performed on the input parameters directly.Some algorithms may use data transforms, that may be generated for aparticular application, or use standard techniques, such as, forexample, various types of signal analysis. Also, artificial intelligencebased calculations may be used, such as, rule-based methods fordiagnosis of specific conditions, and/or complex calculations based onneural networks that may be applied to complex pattern recognition insignal analysis.

Data analyzer layer 410 may be embodied in software executing in DCS 20,or a separate analyzer communicatively coupled to data bas 406. Dataanalyzer layer 410 may also be embodied in one or more hardwareanalyzers such as, circuit cards, application specific integratedcircuits (ASIC), and/or analog or digital logic circuits.

CIMMS 114 may include a plurality of software layers 414 communicativelycoupled to data bus 406. Software layers may include a derived quantitylayer 416 that may use data available in the DCS hardware layers 402 tocompute values for parameters that can not be measured directly because,for example, the parameter is not instrumented. For example, head lossremote from a point in a pipe that is instrumented may be computed basedon known values of pressure, flow, fluid dynamics and pipingcharacteristics. Each derived quantity may have differing levels ofcertainty from each other based on the amount of data available forcomputing that particular derived quantity, for example, a pressuresensor used to compute one derived quantity may have a larger or smalleraccuracy compared to a pressure sensor used to compute another derivedquantity. Derived quantity layer 416 may use a plurality of pressuresensors to compute a single derived quantity. Derived quantity layer 416may determine the derived quantity using the pressure sensor thatexhibits the greatest accuracy at the time of measurement. At a latertime, under different operating conditions, derived quantity layer 416may select a different pressure sensor to compute the derived quantity.Alternatively, derived quantity layer 416 may select both pressuresensors to compute the derived quantity, but may weight each pressuresensors contribution to the calculation based on an operating conditionof the system. Derived quantity layer 416 may compute a derived quantityfor any desired parameter in plant 10 that can be equated to one or moremeasured parameters within plant 10.

Derived quantity layer 416 may also compute confirmatory sets of datathat relates to measured quantities in plant 10. For example, derivedquantity layer 416 may use measured process parameters received fromhardware layers 402 for comparison to values that are derived from othermeasured process parameters and/or other derived quantities to confirmoperability and/or accuracy of sensors and/or data processing devices.For example, vibration data received from a pump may indicate a markedincrease in one or more vibration parameters. Derived quantity layer 416may use measured and/or derived quantities, such as, but, not limitedto, pump flow, outlet pressure, motor current, and/or other industrialplant measured parameters to confirm the nature of the problem with thevibrating pump. Such an analysis occurs in real-time using measuredquantities of the associated motor/pump combination, other systemmeasured parameters, and/or derived quantities. Further analysis may beinitiated to increase the data available for pump diagnosis and/orcondition assessment. For example, derived quantity layer 416 maytransmit the received vibration data to a vibration analyzer for furtherdata extraction. The extracted data combined with the measuredquantities of the associated motor/pump combination, the other systemmeasured parameters, and/or the derived quantities may then be used todetermine the pump condition.

A rule set layer 418 includes a predefined set of rules for eachequipment combination 300 and each individual piece of equipment inindustrial plant 10. Such rule sets may take data for a given scenario,for example, a motor/pump combination and automatically calculate anddetermine performance or faults based on given inputs. Rule sets are agrouping of rules based on domain knowledge that has been learned on themachinery and performs a set of calculations and analysis without theneed for the domain knowledge expert.

A recommendation layer 420 monitors measured process parameters, derivedquantities, signal processing algorithms, analyzer outputs, and accessesrule sets to determine trigger points for equipment conditions. Thetrigger points are used to initiate actions, such as, recommendingadditional data collection, for example from portable data collectors orequipment not integrated into the DCS 20 or CIMMS 114. Other actions mayinclude recommending a mitigating procedure, such as a script ofcommands that, if selected, may initiate mitigating steps, such as,shutting down affected equipment, lining-up alternate flow paths, andstarting up equipment combinations that are redundant to the affectedequipment. Recommendation layer 420 may recommend a maintenanceprocedure that may initiate commands to place an affected equipmentcombination in a condition for performing maintenance activities on theequipment combination. Additionally, recommendation layer 420 may useinteraction online technical manual to display design drawings andprocedures to maintenance personnel during a maintenance procedure sothat manually collecting data and inspection results may be updatedimmediately and be made immediately available to plant engineering andoperations personnel. Recommendation layer 420 may use the enteredmanually collected data and inspection results to apply other rules fromrule set layer 418 to make further recommendations. For example, amicrometer reading of a pump shaft dimension may indicate a criticalparameter has been exceeded and that instead of a simple repair in thefield, a shop rebuild is necessary to return the pump to an operablecondition. Recommendation layer 420 may recommend an operating procedureas a result of evaluating measured process parameters, derivedquantities, and the rules stored in rule set layer 418. The operatingprocedure may guide operating personnel through a series of steps thatmay prolong the life, mean time between failures, and/or extendoperability to a next outage. Operating procedure may use rule set 418to recommend alternate operating cycles, expanding operational limits tosecondary limits, and postponing routine procedures that stress affectedequipment.

A display layer 422 generates display output that may be transmitted tomonitors, printers, data files, and/or other software modules foranalysis and/or forwarding to a pager and/or e-mail client. Displaylayer 422 may format the display output according to user selectableinputs. Such displays may include, but are not limited to currentvalues, a bargraph, a machine train diagram, an alarm/system event list,a trend/multivariable trend, a tabular list, a timebase, anorbit/timebase, orbit, a shaft average centerline, a spectrum/fullspectrum, an x vs. y, waterfall/full waterfall, a polar/acceptanceregion, a bode, a cascade/full cascade, a reciprocating compressor plot,a rod position, a compressor map, a P-V diagram, a Log P versus Log V, apressure versus crank angle, a polar, and a phasor plot.

FIG. 5 is a data flow diagram of an exemplary data flow path formonitoring an equipment combination 300 (shown in FIG. 3). Driver/drivencombination 300 includes a driver machine, such as a turbine, engine,and/or motor 302, a driven machine, such as a generator, compressor,and/or pump 304. Motor 302 and pump 304 are typically coupled together,by their respective shafts, through a variable speed coupling, agearbox, a belt and pulley arrangement, or other coupling device (shownin FIG. 3). Motor 302 and pump 304 may be monitored by a suite ofprocess, environmental, and machine sensors (shown in FIG. 3). Outputsfrom these sensors may be transmitted via various data collectioninstruments through one or more data transmission conduits, for example,but not limited to, a fiber optic cable 502, a copper cable 504, such asa twisted pair cable, a wireless connection 506, and a digital networksegment 508. One or more data collection devices 510, 512, and 514receive signals from the sensors and may preprocess at least a portionof the signals before transmitting data representative of the sensoroutputs to DCS 20. Process data from a plurality of locations inindustrial plant 10 may be collected using a field input/output (I/O)cabinet 516 that may preprocess the process data before transmitting theprocess data to DCS 20. One or more databases may store offline data518, for example, but not limited to, machine nameplate data, industrialplant and component design data, component maintenance history,including inspection results and temporary operating limitations, andother periodically updateable data that facilitates deriving operatingparameters using measured parameters.

DCS 20 is provided with predetermined logic for receiving measuredparameters from equipment located in industrial plant 10 or locallyremotely but, associated with industrial plant 10, and developingcontrol outputs to modify industrial plant equipment. A continuousintegrated machinery monitoring system CIMMS 114 may communicatebi-directionally with DCS 20 over one or more network segments 520 ormay be integral to DCS 20 and execute on processor 24. CIMMS 114includes a database of rule sets that are configured to monitorindustrial plant equipment using measured parameters and derivedquantities based on measured parameters and offline data 518. The rulesets include rules that direct analysis of rule set inputs and place aresult of the analysis on outputs of the rule set. Rule sets may includerules specific to a plant asset, such as a motor/pump combination, ormay include rules specific to an industrial plant system, such as acooling water system. Rule sets may be applied to more than one plantasset and operate to relate the output of the rule set to inputparameters using one or more algorithms, signal processing techniques,and/or waveform analysis parameters. When applied to a specific plantasset, such as combination 300, the rules in rule set 280 use measuredparameters and derived quantities for plant equipment and driver/drivencombinations that may be fluidly communicating with combination 300 butare located remotely. As such, the derived quantities associated withother plant equipment may be used to verify measured parametersassociated with combination 300 and provide information about parametersassociated with combination 300 that cannot be measured directly due to,for example an absence of a sensor capable of measuring the parameter ora sensor malfunction.

When a failure is detected and/or predicted, CIMMS 114 may provide inputto DCS 20 to initiate automatic control action to mitigate the effects othe failure and/or may provide an operator with notification of thefailure and may generate a recommendation for action to be taken by theoperator.

A technical effect is to integrate monitoring and control functions andexpert system analysis into a decision system that operates with aplurality of data sources for substituting derived quantities of processparameters to facilitate analyzing equipment combination health andverifying sensor health and accuracy. The integration allows rule setsto govern monitoring, control, analysis, and maintenance by producingrecommendations based on continuously updated contemporaneous data toensure the best decision can be made. The rule sets are updateable basedon comparing actual findings in the field to recommended procedures.

While the present invention is described with reference to an industrialplant, numerous other applications are contemplated. It is contemplatedthat the present invention may be applied to any control system,including facilities, such as commercial facilities, vehicles, forexample ships, aircraft, and trains, and office buildings or a campus ofbuildings, as well as, refineries and midstream liquids facilities, andfacilities that produce discrete product outputs, such as, factories.

The above-described real-time equipment monitoring system iscost-effective and highly reliable system for monitoring and managingthe operation and maintenance of facilities. More specifically, themethods and systems described herein facilitate determining facilitymachine health in real-time and recommending actions to correct ormitigate the effect of unhealthy or failed machines. As a result, themethods and systems described herein facilitate reducing operating costsin a cost-effective and reliable manner.

Exemplary embodiments of real-time equipment monitoring systems aredescribed above in detail. The systems are not limited to the specificembodiments described herein, but rather, components of each system maybe utilized independently and separately from other components describedherein. Each system component can also be used in combination with othersystem components.

While the invention has been described in terms of various specificembodiments, those skilled in the art will recognize that the inventioncan be practiced with modification within the spirit and scope of theclaims.

1-8. (canceled)
 9. A method of analyzing the health of an equipmentcombination operating in a system that includes a plurality of otherequipment combinations coupled to the equipment combination throughconduits, and wherein the equipment combination includes a drivermachine and a driven machine coupled in rotational synchronicity, saidmethod comprises: receiving a measured process parameter associated withthe driver machine; receiving a measured process parameter associatedwith the driven machine; receiving at least one measured processparameter associated with the plurality of other equipment combinations;and deriving a process parameter quantity for at least one of themeasured process parameter associated with the driver machine and themeasured process parameter associated with the driven machine using theat least one measured process parameter associated with the plurality ofother equipment combinations.
 10. A method of analyzing the health of anequipment combination in accordance with claim 9 wherein deriving aprocess parameter quantity comprises deriving a process parameterquantity for a parameter that is not instrumented.
 11. A method ofanalyzing the health of an equipment combination in accordance withclaim 9 wherein deriving a process parameter quantity comprises derivinga process parameter quantity for a parameter that is measured by atleast one process sensor wherein the derived process parameter quantityis compared to a respective measured process parameter to verify anoperability of the at least one sensor.
 12. An integrated monitoring andcontrol system for a plant wherein the plant has a plurality ofequipment combinations that are operable interactively with each otherand with individual equipment and wherein the combinations are operableto maintain selected plant operational conditions, said monitoring andcontrol system comprising: a plurality of sensors operatively coupled tothe equipment combinations, the plurality of sensors measuring processparameters for monitoring plant operation and assessing equipmentcombination condition, and providing output signals to said monitoringand control system; a derived quantity layer communicatively coupled toa data bus, said derived quantity layer configured to: receive themeasured process parameters; and compute values for process parametersusing the measured process parameters; a rule set layer comprising atleast one rule associated with at least some of the plurality ofequipment combinations for determining a health of the equipmentcombination; and a recommendation layer for correlating the health ofthe equipment combination to at least one of a mitigating procedure, amaintaining procedure, and an operation procedure.
 13. An integratedmonitoring and control system for a plant in accordance with claim 12further comprising a communications layer for sampling said sensoroutput signals communicatively coupled to the output signals.
 14. Anintegrated monitoring and control system for a plant in accordance withclaim 13 wherein said communications layer is configured to receivenetwork message packets of sensor output data.
 15. An integratedmonitoring and control system for a plant in accordance with claim 13wherein said communications layer is configured to preprocess saidsensor output signals.
 16. An integrated monitoring and control systemfor a plant in accordance with claim 12 further comprising a displaylayer configured to generate graphical representations of measuredprocess parameters and derived quantities.
 17. An integrated monitoringand control system for a plant in accordance with claim 16 wherein saiddisplay layer is configured to generate graphical representations ofmeasured process parameters and derived quantities in at least one ofreal-time, historical values, and a combination of real-time andhistorical values.
 18. An integrated monitoring and control system for aplant in accordance with claim 12 wherein said mitigating procedureincludes selectable control actions that are determined from a rule forat least one of facilitating reducing damage to equipment from anequipment failure, and maintaining the plant in an overall operationalcondition.
 19. An integrated monitoring and control system for a plantin accordance with claim 12 wherein said maintenance procedure includesmaintenance actions that are determined from a rule for at least one offacilitating reducing an equipment outage time, increasing an equipmentcombination availability, and facilitating reducing equipmentcombination failure.
 20. A computer program embodied on a computerreadable medium for monitoring a plant, the plant having a plurality ofequipment combinations operating interactively with each other and withindividual equipment, said program comprising a code segment thatcontrols a computer that receives a plurality of process parameters fromsensors operatively coupled to the equipment combinations and individualequipment and then: derives values for process parameters using themeasured process parameters; selects a rule from a set of rulescomprising a plurality of commands that direct data analysis for each atleast one of measured process parameter, a derived quantity, a pluralityof measured process parameters and a derived quantities associated withan equipment combination; and recommends at least one of a mitigatingprocedure, a maintaining procedure, and an operation procedure.
 21. Acomputer program in accordance with claim 20 directs the computer toreceive a plurality of process parameters from a portable datacollector.
 22. A computer program in accordance with claim 20 directsthe computer to receive a plurality of process parameters from an onlineprocess monitor.